Automatic standby electric cloths iron

ABSTRACT

An improved electric clothes iron comprises a water tank, chassis, handle, electrically heated soleplate, and steam chamber. The improvement, in one instance, includes heel and toe lifting pistons which are embedded in the soleplate and driven by an electric motor. A grip sensor in the handle triggers the lift piston motor to operate when the user is no longer gripping the handle. The lifting pistons are quickly retracted if the user grabs the handle again. The heated soleplate can be automatically turned off if the iron is left idle too long.

RELATED APPLICATIONS

This application is a continuation of U.S. utility application Ser. No.11/434,650, filed May 15, 2006, now U.S. Pat. No. 7,546,701, whichclaimed priority of U.S. provisional application Ser. No. 60/680,566filed May 13, 2005. U.S. Ser. No. 11/434,650 is also acontinuation-in-part of U.S. utility application Ser. No. 11/137,921,filed May 25, 2005, now U.S. Pat. No. 7,406,783, which is a continuationof U.S. utility application Ser. No. 10/253,181, filed Sep. 23, 2002,now U.S. Pat. No. 6,925,738, which is a continuation of U.S. utilityapplication Ser. No. 09/861,166, filed May 18, 2001, now U.S. Pat. No.6,453,587. The disclosures of these applications are hereby incorporatedby reference in their entirety.

FIELD OF THE PRESENT INVENTION

The present invention relates to electric clothes irons, and inparticular to safety and convenience devices included in such irons toprevent the iron from burning things when laid down flat or wastingenergy when left unattended.

BACKGROUND

An electric clothes iron consists essentially of a heated sole platethat is pressed against fabric to remove wrinkles. To be effective, thesole plate of an iron must be very hot. Thus, there is a serious dangerof burning the fabric or ironing board or even igniting a fire from anelectric iron inadvertently left unattended. In addition, irons arerelatively heavy, and awkward. Lifting and placing an iron on its tailcan be physically straining on the operator's wrist. Furthermore, whenthe iron is placed on its tail, the hot sole plate is exposed and maycause accidental contact with the sole plate by the user can result insevere burns.

The inventor describes several solutions to these problems in U.S. Pat.No. 6,453,587, issued Sep. 24, 2002, and U.S. Pat. No. 6,925,738, issuedAug. 9, 2005; which patents are hereby incorporated by reference intheir entirety. Here, the iron's hot sole plate is moved away and liftedoff the surface it may be resting on. Non-heated heel and toe pistonswill emerge from the bottom surface after the user lets go of thehandle. The pistons lift the hot sole plate far enough away to preventgarment damage and/or fires, and the electric power may be cut to thesole plate heaters so it will eventually cool down and be safe.

User, manufacturing, and sales experience with these products has leadto many ways that these newest electric clothes irons can be furtherimproved. For example, if an iron is left laid flat on its soleplate,its lifting mechanism should not cause it to roll over on its side. Thelifting mechanism should also not interfere with the basic functionalparts of the iron, such as the water tank, chassis, soleplate or steamchamber parts.

SUMMARY OF THE PRESENT INVENTION

Briefly, an electric clothes iron embodiment of the present inventioncomprises a water tank, chassis, handle, electrically heated soleplate,and steam chamber. In one instance, heel and toe lifting pistons areembedded in the soleplate and driven by an electric motor. A grip sensorin the handle triggers the lift piston motor to operate when the user isno longer gripping the handle. The lifting pistons are quickly retractedif the user grabs the handle again. The heated soleplate can beautomatically turned off if the iron is left idle too long.

An advantage of the present invention is a clothes iron is provided thathelps its users avoid damage to garments and work surfaces, and improvesoverall safety of use.

The above summary of the present invention is not intended to representeach disclosed embodiment, or every aspect, of the present invention.Other aspects and example embodiments are provided in the figures andthe detailed description that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention may be more completely understood in considerationof the following detailed description of various embodiments of thepresent invention in connection with the accompanying drawings, inwhich:

FIG. 1 is a perspective view diagram of an electric clothes ironembodiment of the present invention showing two self-lifting legsextended out through the base of soleplate;

FIGS. 2A-2B are side view diagrams of an exemplary lifting mechanismused inside the iron of FIG. 1, FIG. 2A shows the lifting legsretracted, and FIG. 2B shows them extended;

FIGS. 2C and 2D show an embodiments of the iron including apparatus forinhibiting mineral build-up in the steam chamber.

FIGS. 3A-3C are perspective view diagrams of a lifting mechanism driveshaft in three states: legs raised, legs extended, and intermediate;

FIGS. 4A-4B show a cross-sectional view of a steam release cam and dripvalve useful in the clothes iron of FIG. 1;

FIG. 5 is an exploded assembly view of a clothes iron subassembly usefulin the iron of FIG. 1;

FIG. 6 is a partial cutaway diagram of a handle for the iron of FIG. 1and includes capacitive sensors to detect a user's grip;

FIG. 7 is a partial cutaway of the rear of a clothes iron embodimentwhich details a leg position sensor assembly;

FIG. 8 is a bottom perspective view of a clothes iron with the toepiston fully retracted;

FIG. 9 is a bottom view of an iron showing the semicircular shapes ofthe feet which reduce the contact area between the feet and the fabricwhen the legs are extended;

FIG. 10 is a side view diagram of a soleplate and legs when the feet arefully retracted;

FIGS. 11A-11B are perspective views of a clothes iron with a fill portopen (FIG. 11A) and closed (FIG. 11B);

FIGS. 11C-11D are cross-section views of the fill port of FIGS. 11A-11B;

FIGS. 12A-12B show an alternate embodiment of the present invention witha low thermal mass separation sheet;

FIG. 13A-13B show an alternate embodiment of the present invention inwhich separation of the soleplate and the ironing surface isaccomplished by means of a weight shift;

FIGS. 14A-14B show another embodiment of the present invention wherebyseparation of the soleplate and the ironing surface is accomplished bymeans of a user pressing down on button;

FIGS. 15A-15B show an alternative embodiment of the present inventionthat has no handle;

FIGS. 16A-16B show an alternative leg construction with a low thermalmass layer on the bottom;

FIG. 17 is a flowchart diagram of a control process for the iron of FIG.1; and

FIGS. 18A and 18B diagram the way the lifting mechanisms accelerate anddecelerate during their operation.

FIG. 19 shows an embodiment of the iron of the invention including anexternal steam generation apparatus.

FIG. 20 shows an embodiment in which the motor turns the cam and thewater pump.

While the present invention is amenable to various modifications andalternative forms, specifics thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit the presentinvention to the particular embodiments described. On the contrary, theintention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the present invention as definedby the appended claims.

DETAILED DESCRIPTION

The invention includes a clothes iron including features and advantagesas described further below.

FIG. 1 represents an improved electric clothes iron embodiment of thepresent invention, and is referred to herein by the general referencenumeral 100. The iron 100 comprises a housing 102, a handle 104 on top,a chassis 106, an electrically heated soleplate 108, and two legs 110extending out through the base of the soleplate. Although the iron isshown with an electrical cord, the iron could also be cordless, usingbatteries for power.

FIGS. 2A-2B represent a lifting mechanism 200 comprising a geared DCmotor 202 mounted at the back, a driveshaft 204 that runs from the backto the front, lifting cams 206 and 208, legs 210 and 212, and a steamrelease cam 214. FIG. 2A shows the legs 210 and 212 when retracted upinside a heated soleplate 216, and FIG. 2B shows legs 210 and 212extended out for lifting the iron up off the work surface.

Most modern irons can produce steam. In some irons, mineral build up inthe steam chamber and the apertures in the soleplate with which thesteam is emitted onto the object to be ironed can experience mineralbuild up. In an alternate embodiment of the invention, the drive shaft204 turns the cam 217. The motion of the cam 217 may be used to reducesuch deposits, and or to prevent blockage of the steam apertures in thesoleplate. FIG. 2C shows an embodiment of the invention including asilicone cap on a steam chamber. The cam 217 acts upon the silicone cap219 to cause pressure changes that may inhibit mineral build up in thesteam chamber or prevent blockage of the steam apertures in thesoleplate.

FIG. 2D shows another alternate embodiment for reducing mineral build-upin the steam chamber. In this embodiment, the drive shaft 204 extendsthrough the steam chamber 227. Seals 223 and 225 on each end of thesteam chamber 227 prevent steam from exiting along the drive shaft 204.Drive shaft 204 may include flanges or alternatively brushes 221 whichagitate the water, or alternatively scrape the sides of the steamchamber 227 to prevent mineral build-up.

The legs may be limited to vertical motion by self-lubricating rails onthe front foot and oil impregnated bushings on the rear foot. As themotor turns the shaft, the cams slide side-to-side in the slots whilepushing the feet up or down. Such lifting mechanism improves over theprior art in that it does not interfere with conventional water tank,chassis, soleplate, or steam chamber configurations.

A leg position sensor can be used for detecting the lift height of theseparation mechanism, and for using feedback to control a simple DCmotor or other known actuation means to ensure exact extended orretraced position of the legs. When such feedback is not available, amore expensive stepper motor may be needed to be able to control thelift and lowering cycles. Such leg position feedback mechanism is animprovement over the prior art because it allows for a more accuratemeasurement of leg position. The iron can be placed in an energy savingmode if a microprocessor controller detects that the position of thelegs have not changed for a selected period of time.

FIGS. 3A-3C represent a lifting mechanism 300 in three positions similarto that in FIGS. 2A-2B and useful in the iron of FIG. 1. The liftingmechanism 300 includes a crankshaft 302 connected by lifting cams 304and 306 to a toe piston 308 and a wide heel piston 310. The ends oflifting cams oscillate in slots 312 and 314 and translate the crankshaftrotations into a vertical reciprocating motion for the lifting pistons.Any tendency for toe piston 304 to wobble may be limited by a guide railmounted on chassis 316. Similarly, wobble for heel piston 310 may belimited by guide bushings.

FIGS. 3A-3C help illustrate the interaction of the crankshaft, liftingcams, pistons, and slots. FIG. 3A shows the pistons fully retracted,FIG. 3B shows them fully extended, and FIG. 3C shows the liftingmechanism in the intermediate halfway position.

FIGS. 4A-4B illustrate a steam control subsystem 400. Steam is onlyallowed when a lifting toe piston 402 is fully retracted into itsbeveled recess 404, as in FIG. 4A. Heat from a heated soleplate 406 isisolated from the toe piston 402 so the end of the toe piston will notburn the working surface the iron may be laid upon when the iron liftsup. A crankshaft 408 is driven by an inexpensive motor and turns both apiston lift cam 410 and a steam control cam 412. A steam valve 414 isonly opened when the steam control cam 412 is rotated straight up,corresponding with the piston lifting cam 410 being straight up too. Thetoe piston 402 is in its fully retracted position and the iron is readyfor work.

FIG. 4B shows crankshaft 408 rotated 180-degrees from that shown in FIG.4A. The toe piston 402 is fully extended, and steam control cam 412 hasallowed steam valve 414 to close.

FIG. 5 shows an iron subassembly 500 comprising a chassis 502, a heatedsoleplate 504, a toe piston 506, a toe cavity 508, a heel piston 510,and a heel piston sealing cover 512. The chassis 502 is molded so thattoe cavity completely covers toe piston 506 and blocks any steam orwater from coming back up from the working surface into the iron'sinterior. Similarly, the heel piston sealing cover 512 keeps moisturefrom getting past it into the interior electrical circuits where thedampness could cause trouble.

Generally the iron is activated by a sensor which detects when theoperator touches or grasps the handle of the iron. However, the sensorcould also detect the proximity of the user or the user's hand, and instill other embodiments, the sensor might take the form of a manuallyoperated switch activated by the user. FIG. 6 shows a partial cutaway ofa handle 600 with a capacitive touch sensor circuit 602. A pair ofcapacitor electrodes 604 and 606 comprise conductive coatings or tapeinside a hollow plastic handle core. Circuit 602 contacts theseelectrodes through a pair of contact springs 608 and 610. It senses whena user grips the handle, and a microprocessor may be used to interpretthe signals and control the lifting mechanisms.

FIG. 7 represents a leg position sensor 700 disposed in the rearinterior of an iron like that of FIG. 1. Two Hall effect sensors 702 and704 measure their positions relative to a heel piston magnet 706. Any ofa large number of conventional position sensing technologies could beused instead, what's illustrated here is merely an example of onepractical way to implement such sensor.

FIG. 8 represents a front lift mechanism 800 embedded in a heatedsoleplate 802 and mounted to a chassis 804. A heat insulator 806 comesbetween a toe piston 808 and the heat generated in soleplate 802. Suchheat insulator 806 can either be mounted to the soleplate 802 or the toepiston 808.

FIG. 9 represents a clothes iron embodiment of the present invention andis referred to herein by the general reference numeral 900. Viewed fromthe bottom, a soleplate 902 has dozens of steam vents in two groups 904and 906. Semicircular shapes for toe piston 908 and heel piston 912reduce the contact area with the fabric when the legs are extended. Thisminimizes any indentation created by the feet on the fabric.

FIG. 10 represents an iron 1000 with a chassis 1002 that supports asoleplate 104 and a heel piston 1006. Since this is a side view, the gapbetween heel piston 1006 and soleplate 1004 can be readily seen. Theheel piston 1006 is in its fully retracted position.

FIGS. 11A-11B show a clothes iron 1100 with a fill port 1102 open inFIG. 11A, and closed in FIG. 11B. FIGS. 11C-11D provide more detail. Asseen here in cross-section, fill port 1102 includes a large ball joint1104 with a conduit 1106 and a funnel section 1108 that receive waterfor a reservoir tank 1110. The tank 1110 is sealed off when the fillport 1102 is in the closed position of FIG. 11C. In FIG. 11D, the fillport 1102 has been flipped open, and a direct path for fill water leadsfrom funnel section 1108 to conduit 1106 to tank 1110. When full, thefill port 1102 is flipped back into the housing. After ironing, the usercan drain any remaining water from the clothes iron by tilting itforward and pouring out the water through a drain port located on thefront of the handle.

Another basic embodiment of a clothes iron embodiment of the presentinvention is shown in FIGS. 12A-12B. An improved clothes iron 1200 isprovided with a low thermal mass separation sheet 1202. Such separationsheet cools off very quickly when not in intimate contact with a heatingplate 1204, as in FIG. 12A. A pair of pistons 1206 and 1208 controlwhether separation sheet 1202 should contact the heating plate 1204, asin FIG. 12B.

FIG. 13A-13B show another clothes iron embodiment of the presentinvention, and is referred to herein by the general reference numeral1300. When a weight 1302 is positioned forward, as in FIG. 13A, the iron1300 will naturally rest on its bottom ironing surface 1304. If the iron1300 is left in this position unattended too long when powered on, thena motor is used to move the weight 1302 far to the rear. The change inthe center of gravity causes the iron to rock back and stand on a heelplate 1306, as in FIG. 13B.

A still further clothes iron embodiment of the present invention isrepresented in FIGS. 14A-14B, and is referred to herein by the generalreference numeral 1400. Iron 1400 has a highly simplified liftingmechanism. A simple button 1402 is pressed down and a linkage causesfront and rear legs 1404 and 1406 to emerge from a soleplate 1408, as inFIG. 14A. The button 1402 is pressed again to release a lock and legs1404 and 1406 are retracted back into soleplate 1408.

FIGS. 15A-15B show an alternative clothes iron embodiment of the presentinvention that has no handle, and is referred to herein by the generalreference numeral 1500. A housing 1502 is designed to fit into the palmof a user's hand. A separation mechanism 1504 and 1506 does not requirethe user to lift the iron, so it is possible to eliminate theconventional iron handle and only have a rounded top surface. Thiscreates a more multidirectional iron, allowing the iron to be morecircular and allowing the user to grip the iron in any orientation.

FIGS. 16A-16B show an alternative lifting mechanism leg construction1600. In FIG. 16A a leg 1602 is extended. A pad 1604 is attached at thedistal end and is constructed of a material with a low thermal mass.FIG. 16B shows leg 1604 retracted, and the pad 1604 closes contact withan iron soleplate 1606. When the separation mechanism lowers the iron tothe ironing surface, the pad 1604 will heat up quickly to the soleplatetemperature, providing a smooth, continuous heated surface. When theseparation mechanism raises the iron, the pad 1604 will quickly cool toroom temperature.

A clothes iron control process embodiment of the present invention isdiagrammed in FIG. 17, and is referred to herein by the generalreference numeral 1700. Process 1700 begins with a step 1702 when theiron is powered. If the separation or lifting mechanism is enabled,control passes to a step 1704. A sensor is read to see if the iron ishorizontal, vertical, or on its side. If horizontal, flat on its bottom,a step 1708 starts an eight minute timer. If vertical, standing up onits heel a step 1710 starts an eight minute timer. If on its side, astep 1712 starts a thirty second timer. If the iron is idle andhorizontal for too long, a step 1714 turns off the heated soleplate. Ifthe iron is idle and vertical for too long, a step 1716 turns off theheated soleplate. If the iron is idle and on its side for longer thanthirty seconds, a step 1716 turns off power to the heated soleplate.

If the separation or lifting mechanism is disabled, control passes to astep 1720. A sensor is read to see if the iron is horizontal, vertical,or on its side. If horizontal, flat on its bottom, a step 1722 starts athirty second timer. If vertical, standing up on its heel a step 1724starts an eight minute timer. If on its side, a step 1726 starts athirty second timer. If the iron is idle and horizontal for too long, astep 1728 activates the lifting mechanism. If the iron is idle andvertical for too long, a step 1730 turns off the heated soleplate. Ifthe iron is idle and on its side for longer than thirty seconds, a step1732 turns off power to the heated soleplate. If after lifting andseparating in step 1728, thirty seconds more has elapsed and the ironhas been idle, then a step 1734 turns off power to the soleplate.

FIGS. 18A-18B represent the speed at which the lifting and separatingmechanisms operate over time and separation distance. A lifting curve1800 begins slowly and gains speed, it decelerates at the end of thelift. Similarly, a retraction curve 1802 descends slowly at first, thendrops more rapidly, and finishes with a slow careful landing.

In general, the separation mechanism when activated should minimize anyindentations that will be left in the fabrics of the clothes beingironed. Ideally, the shape of the area itself in contact with the fabricshould be reduced while still allowing for stability. The separationmechanism should not catch or bind on fabrics when the iron is in use.And if the iron were tilted slightly to one side, the iron should beable to right itself automatically. Half circle leg ends can providemaximum stability with minimal contact area. Recesses in the soleplatehelp reduce snagging when the legs are retracted deeper into thesoleplate.

Separation mechanism pieces that operate through ports in the soleplatemust be insulated from the heated parts so they will not bum the fabricor work surfaces when the irons lifts off. High-temperature plastics orceramics are insulated from the soleplate wherever they pass through. Ifthe distal tip of the lifting legs are made of low thermal mass andhighly heat conductive materials, then when retracted they could helpspread working heat across the lifting port openings for more uniformironing. Such would cool quickly to room temperature when the separationdevice was activated to separate the iron from the ironing surface. Theadvantage of this configuration would be that the separation device ifgoing through the soleplate would not create cold spots.

In one embodiment, a front leg passes through a sleeve of insulatingmaterial connected to the chassis. Or the sleeve could be attached tothe leg as an integrated layer of insulation. The rear leg is placed aftof the hot soleplate, and the air gap between the leg and the soleplateacts as the insulator.

Steam and moisture must be prevented from backing up through any portsprovided in the soleplate for the lifting mechanism. Such unwanted steamand moisture inside the iron can damage the interior parts, and shortout the electronics. A physical barrier between the lifting mechanismand other sensitive iron components is a good way to prevent suchproblems. The steam chamber is very difficult to seal, so the bestlifting mechanism implementations will not require modifications toconventional steam chambers.

The chassis should be implemented such that it completely seals over thetop of the front foot. A secondary cover over the back foot is used toseal it. These covers should completely encase both feet, and work as abarrier between the steam and the internal parts of the iron. Both thefront and back feet are placed just outside dimensions of the steamchamber, so the steam chamber volume can be maximized and uninterrupted.

Embodiments of the present invention generate steam when in thehorizontal lifted position. Conventional irons use gravity to controlsteam generation and a passive steam valve. When a conventional iron ishorizontal, the water in the tank is allowed to drip down onto the hotsoleplate, creating steam. In the vertical position, the supply water isprevented from dripping down, so the steam will deplete. But becausesteam iron embodiments of the present invention always remainhorizontal, it is advantageous to have an active steam valve to turn thesteam on only when the user wishes to iron. This can be accomplishedusing the separation mechanism movement, a valve that is directlycontrolled by the microprocessor, a switch activated by the users touch,or a mechanical connection between the user's hand and the valve.

In one embodiment, cams mounted on the separation mechanism shaft areused to open and close drip valves and therefore the amount of steamproduced. The cams are aligned so that the drip valves are open onlywhen the feet are retracted. Alternative methods include a valve drivenby a motor independent of the leg actuating motor, or a valvemechanically opened and closed by a button or mechanical lever on theoutside of the iron. An active steam valve in an iron can be used toregulate when steam is available, e.g., to use make steam in a verticalposition to steam hanging clothes.

Under normal use, iron embodiments of the present invention do not needto stand vertically. So the water filling port can be placed on the sideor the top of the housing so the user can fill the iron while it wasstanding in the horizontal position on its legs. A ball-joint and o-ringsystem is used to create a water tight seal when the fill port isflipped closed. A side-located fill port allows the iron to be filled inany sink, not just ones with high faucets as needed by conventionalirons. Since the fill port is not confined to the handle, as on existingirons, a wide built-in funnel can be included.

There are cases when users would wish to disable the separationmechanism entirely. A means, such as a switch, can be provided to allowthe user this option.

The back end can be configured to allow the iron to rest in the verticalposition, a sensor keeps the legs retracted. The controller can overridethis if it detects that the iron has not been used in an extended periodof time, e.g., to extend the legs to ensure that the fabric or ironingsurface is not burned.

If the iron is left unattended too long in any position, it isadvantageous that the iron shut off the heating element after aspecified period of inactivity in order to conserve energy and preventpotential hazards resulting from the hot soleplate.

Any embodiment can use position sensors in the legs to determine whetherthe legs have been extended for a specified period of time, indicatingthat the iron is not being used. After the specified period of time, themicroprocessor cuts power to the heating element. The next time the ironlowers itself, the microprocessor turns the heating element back on. Inthe case that the user has activated the separation override switch, theiron will rise itself from the iron surface and cut the power to theheating element if left inactive for a period of time. Also ironorientation sensors detect whether the iron has been left vertical foran extended period of time or has been knocked over and will turn offpower to the heating element accordingly.

A motorized shaft also offers opportunities to enhance the steamcapabilities of the iron. In addition to retracting the legs and openingthe valves, the shaft could also be used to pressurize the steam burst,e.g., using a bellows system to pressurize the water before entering thesoleplate. The result would be a spray of water that is rapidlyvaporized, generating a much stronger steam burst.

One alternative embodiment uses no handle. The iron housing is designedto fit into the palm of the user's hand. The separation mechanism doesnot require the user to ever lift the iron, it is possible to eliminatethe handle and only have a rounded top surface. This creates a moremultidirectional iron.

FIG. 19 shows an embodiment of the invention including a separate steamgenerating apparatus 301 that may be coupled to the iron 100 in gascommunication with the steam chamber of the iron 100 so that the iron100 can emit a continuous stream of steam.

FIG. 20 shows an embodiment of the invention wherein the motor 202 canbe turned in either direction, and is geared so that in one directionthe motor acts on the cam 204, and in the other direction, the motor 202acts on the water pump 215. In some embodiments, it may be preferablefor the motor 202 to be prevented from acting on the water pump 215 whenthe legs are extended.

While the present invention has been described with reference to severalparticular example embodiments, those skilled in the art will recognizethat many changes may be made thereto without departing from the spiritand scope of the present invention, which is set forth in the followingclaims.

1. An iron comprising: a soleplate; a handle; a separation mechanismincluding at least one lifting leg for lifting said iron, therebylifting a bottom surface of said soleplate away from a supportingsurface; a sensor providing for control of said separation mechanism,wherein, when said sensor detects the hand of the user contacting saidiron, said sensor sends a signal to said separation mechanism to lowerthe iron by retracting said separation mechanism, and when the userreleases said iron said sensor signals said separation mechanism toraise the iron.